Abstract
Pressure limitations often prohibit engineers from placing
frac-pack sand-control treatments where they are needed the
most because of the collapse ratings of the bottomhole
assembly equipment. Often, these pressure limitations lead to
early abandonment of the well, or they create problems later in
the life of the well, because they do not allow for effective
sand-control, which inevitably will have a negative impact on
well economics. A new method, dynamic pMAX, used to
determine the amount of pressure exerted on the bottomhole
tools during the sand-control treatment, enables frac-pack
treatments that the industry once would have considered
impossible to achieve.
Introduction
Sand control methods were first implemented in order to
control the flow of fines during the production of
hydrocarbons. Initially, fines control was limited to standalone screens and consolidation treatments; however, as
technology progressed, new methods of sand control were
attained.1 The most notable of these new methods was the frac
pack, which became commonplace in the late 1980s and early
1990s for completing formations with high permeability. Fracpacks provide long-term stimulation similar to hard-rock
hydraulic fracturing treatments, and they control the
encroachment of small sand particles from soft formations.2
Although the frac pack could provide the capability to
stimulate the formation as well as control the formation fines,
high flow rates often induced proppant flow back. This
problem was best solved through the use of downhole tools.
Unfortunately, pressure limitations for the tools could impose
limits on the types of sand-control jobs that could be pumped,
and when modeling the maximum pressure for each job,
planned frac packs had to be cancelled due to the pressure
restrictions.
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completion and above the FLD are the lower casing extension,
the closing sleeve, the upper casing extension, and the gravel
pack packer, through which the multi-position tool is situated.
The multi-position tool is illustrated in Fig. 2. The
purpose of this tool is to direct fluid and proppant from the
tubing to the formation without disturbing the screen.
Fluid moves out of the tubing by means of a cross-over
placed across the closing sleeve in the assembly. The multiposition tool has three positions the circulating position, the
squeeze position, and the reverse circulating position. The
circulating position (shown in Fig. 2) allows fluid to flow out
of the tubing, into the screen, and up the annulus with minimal
fluid flowing into the perforation unless the annulus is closed
at surface. If the annulus is closed, then the fluid will be
forced into the perforations. Squeeze position, which is shown
in Fig. 3, closes the port to the annulus at the service tool and
forces the fluid into the formation.
Reverse position allows for the fluid on the annulus to be
circulated to the tubing, thereby removing any excess proppant
or under-balanced fluids, as seen in Fig. 4.
By understanding the path of the fluid, it is much easier to
comprehend the components upon which the pressure is
acting, since the pressures affecting the tools take the same
path as the fluid.
Original Formula
Researchers have determined that five parameters affect
collapse of the components below the crossover ports:
Tubing pressure exerted from the surface
Collapse rating of the components in the assembly
The safety factor applied to the components
Reservoir pressure, otherwise known as bottomhole
pressure
Hydrostatic pressure in the workstring.4
From these parameters, engineers developed a
mathematical formula to determine the maximum surface
pump pressure allowed, or pMAX. Eq. 1 represents the
maximum pressure:
PMAXP= pPackerDifferenti
c
alRating ptub_ hydrostat
+ pAnn_ hydrostati
c + pannulus
. . . . . . . . . . (2)
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p hydrostati
= (. 052 )( )( D )
p tub
_ hydrostati
p tub
_ hydrostati
slurry =
bf + CS
(Cs * VABS ) + 1
(4)
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. . . (6)
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Table 2 Well A and well B after the implementation of the dynamic method. The Pmax has been
increased on each well by 2,500 psi, which is equivalent to the effective BHP.
Well A
Well B
TVD
10,000
ft
TVD
10,000
ft
BHT
150
F
BHT
150
F
BHP
6,500
psi
BHP
3,500
psi
Fluid Wt.
13.00
ppg
Fluid Wt.
8.60
ppg
Packer Rating
8,000
psi
Packer Rating
8,000
psi
Slurry Density
13.42
ppg
Slurry Density
13.42
ppg
Weaklink
10,500
psi
Weaklink
10,500
psi
10,461
psi
7,422
psi
pMAX
pMAX
Applied BHP
2,500
psi
Applied BHP
2,500
psi
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MULTI-POSITION TOOL
GRAVEL PACK PACKER
FLOW SUB
CLOSING SLEEVE
SCREENS
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Minifrac
A
12000
B
50
F
140
135
10000
40
130
8000
30
6000
125
120
(F)
20
Friction
115
4000
110
10
2000
105
0
23:35
0
23:40
23:45
23:50
23:55
3/3/2003
00:00
00:05
3/4/2003
3/4/2003
100
Time
Fig. 5 Illustrates the mini-frac operation. The applied surface pressure is not reaching bottom because of friction
losses. When the pump shuts down, surface pressure drops by an amount equal to friction-pressure loss.
B
A
Hard Screen-out
10000
12
200
10
190
180
170
160
150
140
20
At 15 BPM
8000
6000
4000
15
10
2000
5
Difference is
friction pressure
loss increase
-2000
0
08:40
08:45
08:50
08:55
09:00
4 /2 9 /2 0 0 2
09:05
09:10
4 /2 9 / 2 0 0 2
Time
Fig. 6 Illustrates a hard screenout.
10
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A
10000
T u b in g P ress u re (p s i)
BH P ro p p an t Co n c (lb /gal)
BH G au ge P res s u re (p s i)
A
B
A
P ro p p an t Co n c (lb /gal)
BH G au ge P res s u re (p s i)
Slu rry T em p eratu re (F )
B
A
J
C
J
14
9000
8000
7000
10
6000
4000
3000
14
12
At 10
BPM
2000
4
2
0 6 :4 0
4 /3 /2 0 0 3
0 6 :5 0
0 7 :0 0
160
150
140
130
1000
170
16
10
J
180
(F)
5000
18
Hard
Screen out
12
C
20
0 7 :1 0
0 7 :2 0
Tim
Time
0 7 :3 0
0 7 :4 0
120
110
100
4 /3 /2 0 0 3
(hrs)
A
12000
B
30
10000
25
A
B
C
D
D
D
D
D
A
C
E
E
E
E
E
6000
20
16
4000
10
2000
14
15
D
200
18
8000
C
20
180
160
12
Static
10
BHP
7,500 psi
6
4
0
22:30
1/8/2003
22:50
23:10
23:30
23:50
Time (hrs)
00:10
00:30
0
00:50
1/9/2003
Fig. 8 This graph shows the net pressure gain. The static BHP recorded by the memory
gauges is approximately 7,500 psi. As the fracturing rate of 25 bbls/min is reached, the
pressure increases to 9,100 psi initially and grows to 10,050 psi at final screenout.
11000
10000
9000
140
8000
120
100
2
0
E
12000
80
7000
6000
5000
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Fig. 9 Graphical representation of actual pressure calculations and recordings taken during the pumping of a frac
pack using only pMAX calculations based on static bottom hole pressure and the changing hydrostatic
pressure in the work string.
Fig. 10 Graphical representation of actual pressure calculations and recordings taken during the pumping of
a frac pack using pMAX calculations based on static bottom hole pressure and the changing
hydrostatic pressure in the work string as well as live annulus pMAX calculations based on bottom
hole treating pressure and the changing hydrostatic pressure in the work string.
11